In addition to manufacturing cost and production rates, damage resistance has become a major issue for the composites industry. Three-dimensional (3D) woven composites have superior through-thickness properties compared to two-dimensional (2D) laminates, for example, improved impact damage resistance, high interlaminar fracture toughness and reduced notch sensitivity. The performance of 3D woven preforms is dependent on the fabric architecture, which is determined by the binding pattern. For this study, angle interlock (AI) structures with through-thickness binding were manufactured. The AI cracking simulation shows that the transverse component is the one that leads to transverse matrix cracking in the weft yarn under tensile loading. Monitoring of acoustic emission (AE) during mechanical loading is an effective tool in the study of damage processes in glass fiber-reinforced composites. Tests were performed with piezoelectric sensors bonded on a tensile specimen acting as passive receivers of AE signals. An experimental data has been generated which was useful to validate the multi-physics finite element method (MP-FEM), providing insight into the damage behaviour of novel 3D AI glass fibre composites. MP-FEM and experimental data showed that transverse crack generated a predominant flexural mode A0 and also a less energetic extensional mode S0.@en

Damage initiation and evolution of three-dimensional (3D) orthogonal woven carbon fibre composite (3DOWC) is investigated experimentally and numerically. Meso-scale homogenisation of the representative volume element (RVE) is utilised to predict the elastic properties, simulate damage initiation and evolution when loaded in tension. The effect of intra-yarns transverse cracking and shear diffused damage on the in-plane transverse modulus and shear modulus is investigated while one failure criterion is introduced to simulate the matrix damage. The proposed model relies on two major assumptions. First, the effect of the binder yarns, on the in-plane properties, is neglected, so the 3DOWC unit cell can be approximated as a (0°/90°) cross-ply laminate. Second, a micro-mechanics based damage approach is used at the meso-scale, so damage indicators can be correlated, explicitly, to the density of cracks within the material. Results from the simulated RVE are validated against experimental results along the warp (0° direction) and weft (90° direction). This approach paves the road for more predictive models as damage evolution laws are obtained from micro mechanical considerations and rely on few well-defined material parameters. This largely differs from classical damage mechanics approaches in which the evolution law is obtained by retrofitting experimental observations.@en

Electrical resistance monitoring (ERM) has been used to study the effect of the z-binding yarns on the initial electrical resistance (ER) and its change of three architectures of 3D woven carbon fibre composites namely (orthogonal “ORT”, layer-to-layer “LTL” and angle interlock “AI”) when tested in tension. Specimens are loaded in on-axis “warp” and off-axis “45°” directions. In situ ERM is achieved using the four-probe technique. Monotonic and cyclic “load/unload” tests are performed to investigate the effect of piezo-resistivity and residual plasticity on resistance variation. The resistance increase for the off-axis loaded specimens (∼90%) is found to be higher than that of their on-axis counterparts (∼20%). In the case of cyclic testing, the resistance increase upon unloading is irreversible which suggests permanent damage presence not piezo-resistive effect. At the moment, it is difficult to obtain a direct correlation between resistance variation and damage in 3D woven composites due to the complexity of the conduction path along the three orthogonal directions, however this study demonstrates the potential of using ERM for damage detection in 3D woven carbon fibre-based composites and highlights the challenges that need to be overcome to establish ERM asa Structural Health Monitoring (SHM) technique for such material systems.@en

Three different architectures of 3D carbon fibre woven composites (orthogonal, ORT; layer-to-layer, LTL; angle interlock, AI) were tested in quasi-static uniaxial tension. Mechanical tests (tensile in on-axis of warp and weft directions as well as 45° off-axis) were carried out with the aim to study the loading direction sensitivity of these 3D woven composites. The z-binder architecture (the through-thickness reinforcement) has an effect on void content, directional fibre volume fraction, mechanical properties (on-axis and off-axis), failure mechanisms, energy absorption and fibre rotation angle in off-axis tested specimens. Out of all the examined architectures, 3D orthogonal woven composites (ORT) demonstrated a superior behaviour, especially when they were tested in 45° off-axis direction, indicated by high strain to failure (∼23%) and high translaminar energy absorption (∼40MJ/m3). The z-binder yarns in ORT architecture suppress the localised damage and allow larger fibre rotation during the fibre “scissoring motion” that enables further strain to be sustained by the in-plane fabric layers during off-axis loading.@en

The effect of circular notch has been evaluated for three different architectures of three-dimensional (3D) carbon fibre woven composites (orthogonal, ORT; layer-to-layer, LTL; angle interlock, AI) through open-hole quasi-static tension and double-lap bearing strength tests in the off-axis (45textdegree) direction. Damage characterisation is monitored using Digital Image correlation (DIC) for open-hole testing and X-ray Computed Tomography (CT) for double-lap bearing strength test. The off-axis notched 3D woven composites exhibits minor reduction (less than 10 %) of the notched strength compared to the un-notched strength. DIC strain contour clearly show stress/strain localisation regions around the hole periphery and stress/strain redistribution away from the whole due to the z-binder existence, especially for ORT architecture. Up to 50 % bearing strain, no significant difference in the bearing stress/bearing strain response is observed. However when ORT architecture was loaded up to failure, it demonstrates higher strain to failure (textasciitilde140 %) followed by AI (textasciitilde105 %) and lastly LTL (textasciitilde85 %). X-ray CT scans reveal the effect of the z-binder architecture on damage evolution and delamination resistance. The study suggests that off-axis loaded 3D woven composites, especially ORT architecture, has a great potential of overcoming the current challenges facing composite laminates when used in composite joints' applications.@en

Three dimensional (3D) woven composites have attracted the interest of academia and industry thanks to their damage tolerance characteristics and automated fabric manufacturing. Although much research has been conducted to investigate their out-of-plane “through thickness” properties, still their in-plane properties are not fully understood and rely on extensive experimentation. To date, the literature lacks an inclusive summary of the mechanical characterisation for 3D woven composites. Therefore, the objective of this paper is to provide a comprehensive review of the available research studies on 3D woven composites mechanical characterisation, with less emphasis on the out-of-plane response, but an in-depth review of the in-plane response “un-notched vs. notched”. The paper highlights the knowledge gap in the literature of 3D woven composites, suggesting opportunities for future research in this field and a room for improvement in utilising Non-Destructive Techniques (NDT), such as Digital Image Correlation (DIC), Acoustic Emission (AE) and X-ray Computed Tomography (CT), for observing damage initiation and evolution in 3D woven composites that could be used to calibrate and evaluate analytical and numerical models.@en